Consumable weight components for flares and methods of formation

ABSTRACT

Flares with consumable weights connected to a forward end of the grain of the flare are disclosed. Also disclosed are consumable weight components for flares. The consumable weight components include a metal material within a matrix. Also disclosed are methods for fabricating a flare and methods for using a flare. Use of the consumable weights in the flares may reduce the amount of debris falling to ground.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. patent application Ser. No.13/289,669, filed Nov. 4, 2011, pending, the disclosure of which ishereby incorporated in its entirety herein by this reference.

TECHNICAL FIELD

The present disclosure, in various embodiments, relates to flares usedin signaling, illumination, aircraft defensive countermeasures, or acombination of several such functions. More specifically, the presentdisclosure relates to flares including consumable weight componentstherein, consumable weight components for flares, and to methods offabricating and using such flares.

BACKGROUND

Flares are pyrotechnic devices designed to emit intense electromagneticradiation at wavelengths in the visible region (i.e., light), theinfrared region (i.e., heat), or both, of the electromagnetic radiationspectrum without exploding or producing an explosion. Conventionally,flares have been used for signaling, illumination, and defensivecountermeasure decoys in both civilian and military applications.

Decoy flares produce electromagnetic radiation through the combustion ofa primary pyrotechnic material that is conventionally referred to as the“grain” of the flare. Flares, including decoy flares, configured to emitlight in a visible spectrum of light may include a grain that includesmagnesium and fluoropolymer-based materials. Including or excludingcertain metals or other materials in the primary pyrotechnic materialmay alter the peak emission wavelength emitted by the decoy flare.

Decoy flares are one particular type of flare used in militaryapplications for defensive countermeasures. Decoy flares emit intenseelectromagnetic radiation at wavelengths in the infrared region of theelectromagnetic radiation spectrum and are designed to mimic theemission spectrum of the exhaust of a jet engine on an aircraft.

Many conventional anti-aircraft heat-seeking missiles are designed totrack and follow an aircraft by detecting the infrared radiation emittedfrom the jet engine or engines of the aircraft. As a defensivecountermeasure, decoy flares are launched from an aircraft being pursuedby a heat-seeking missile. When the aircraft detects that a heat-seekingmissile is in pursuit of the aircraft, one or more decoy flares may belaunched from the aircraft. The heat seeking missile may, thus, be“decoyed” into tracking and following the decoy flare instead of theaircraft.

FIGS. 1 and 2 illustrate a conventional flare 10, such as a decoy flare.Such conventional flares 10 include an elongated grain 22 that isinserted into a casing 12. The casing 12 may have a first end 14, i.e.,the aft end, from which an aft end 23A of the decoy flare 10 is ignited,and a second end 16, i.e., the forward end opposite from the aft end,from which the grain 22 is ejected upon ignition. The flare 10 alsoincludes a weighted end cap 40 that is attached to a forward end 23B ofthe grain 22. In some flares 10, the weighted end cap 40 may include anelongated rod 42 that is configured to be inserted into an internal bore44 within the grain 22 to attach the weighted end cap 40 to the grain22.

The weighted end cap 40 may be formed of a metal, e.g., brass, and mayhave a weight in the range of 30 grams to 50 grams. The weighted end cap40 may be formed as a solid (i.e., monolithic) structure. The weightedend cap 40 is relatively small sized, compared to the grain 22, andrelatively more dense than the grain 22. The majority of the weight ofthe grain 22 and weighted end cap 40, combined, is therefore distributedtoward the forward end 23B of the grain 22 and, thus, of the flare 10.By locating the center of gravity toward the second end 16 of the flare10, the weighted end cap 40 is configured to provide a stable trajectoryto the flare 10 once ejected from the casing 12. In use, once the grain22 of the flare 10 is combusted, the weighted end cap 40 remainsessentially intact and falls to the ground below. The weighted end cap40 falls below and behind the aircraft from which the flare 10 isejected and, thus, presents danger to other airborne aircraft andground-based building, vehicles, and personnel. Since multiple flares 10may be fired at once during many evasive maneuvers, multiple weightedend caps 40 may form a so-called “cloud” of debris that is a danger toaircraft, building, vehicles, and personnel below.

BRIEF SUMMARY

Disclosed herein is a flare comprising a grain comprising a combustiblematerial. The flare further comprises a consumable weight connected to aforward end of the grain. The consumable weight comprises metal materialdispersed in a matrix.

Also disclosed herein is a consumable weight component for a flare, theconsumable weight component comprising a metal material within a matrix.

Also disclosed herein is a method for fabricating a flare, the methodcomprising suspending a metal material within a matrix to form aconsumable weight. The method further comprises affixing the consumableweight to a grain.

Also described herein is a method for using a flare. The methodcomprises providing a flare comprising a combustible grain and aconsumable weight comprising a metal material within a matrix. Themethod further includes combusting the combustible grain to ignite theconsumable weight. The method further includes combusting the consumableweight to produce combustion products comprising gaseous byproducts, afriable material, and unreacted metal material.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

While the specification concludes with claims particularly pointing outand distinctly claiming that which is regarded as the invention,advantages of the invention can be more readily ascertained from thefollowing detailed description when read in conjunction with theaccompanying drawings in which:

FIG. 1 is a perspective view of one example of a flare according to theprior art;

FIG. 2 is a cross-sectional view of the flare shown in FIG. 1;

FIG. 3 is a perspective view of one example of a flare according to anembodiment of the present disclosure;

FIG. 4 is a cross-sectional view of the flare shown in FIG. 3;

FIG. 5 is a simplified drawing showing an enlarged view of the materialwithin a consumable weight of an embodiment of the present disclosure;

FIG. 6 is a perspective view of one example of a consumable weight andgrain that may be used in a flare according to an embodiment of thepresent disclosure, such as the flare shown in FIGS. 3 and 4;

FIG. 7A is a front elevation view of the an embodiment of the consumableweight shown in FIG. 6, and is also a front elevation view of the grainshown in FIG. 6;

FIGS. 7B through 7E illustrate additional examples of consumable weightsor grains that may be used in flares according to an embodiment of thepresent disclosure, such as the flare shown in FIGS. 3 and 4;

FIG. 8 is a cross-sectional view of a grain assembly of the flare ofFIG. 4, taken along line 8-8;

FIG. 9 is a cross-sectional view of an additional example of a grainassembly that may be used in flares according to an embodiment of thepresent disclosure; and

FIG. 10 is a perspective view of another example of a flare according toan embodiment of the present disclosure.

DETAILED DESCRIPTION

The following description provides specific details (such ascompositions, component designs, etc.) in order to provide a thoroughdescription of embodiments of the present disclosure. However, a personof ordinary skill in the art will understand that the embodiments of thepresent disclosure may be practiced without employing these specificdetails. Indeed, the embodiments of the present disclosure may bepracticed in conjunction with conventional systems and methods employedin the industry. In addition, only those process components and actsnecessary to understand the embodiments of the present disclosure aredescribed in detail below. A person of ordinary skill in the art willunderstand that some materials and/or process components are inherentlydisclosed herein and that adding various conventional components orprocess techniques would be in accord with the present disclosure. Thedrawings accompanying the present application are for illustrativepurposes only, and are not meant to be actual views of any particularmaterial, device, or system. Additionally, elements common betweenfigures may retain the same numerical designation.

A flare having a consumable weight component is disclosed. As usedherein, the term “consumable” means and includes a material that is usedup during use and operation of the flare. During use and operation ofthe flare, combustion of the consumable weight produces at least one ofgaseous byproducts, a friable material, and unreacted material, thus,consuming the consumable weight. The consumable weight provides weightand stability to a forward portion of the flare during launch and flightof the flare. As used herein with regard to a flare, the terms “forwardend,” “forward portion,” or “forward weight” of a flare denotes theleading end of the flare when ejected from a vehicle for use, whichvehicle may be in flight, and may be characterized as the leadingportion or end of the flare. Similarly, the term “forward end” of agrain denotes a leading end of the grain during flight, which leadingend may be attached to a consumable weight according to an embodiment ofthe disclosure. The consumable weight is fanned from an energeticmaterial such that the consumable weight combusts during use andoperation of the flare. The consumable weight may, ultimately, beconsumed by converting the consumable material to at least one of thegaseous byproducts, friable material, and unreacted material. Thefriable material may disperse into ash or small particles that do notpose a danger to airborne aircraft or ground-based buildings, vehicles,or personnel, and the unreacted material may be in the form of smallparticles that do not pose a danger to airborne aircraft or ground-basedbuildings, vehicles, or personnel. The nature of the combustion products(i.e., the gaseous byproducts, friable material, and unreacted material)of the consumable weight may reduce the amount of falling debriscompared to that obtained using conventional forward weights inconventional flares.

One example of a flare 110 that embodies teachings of the presentdisclosure is shown in FIGS. 3 and 4. The flare 110 includes a grainassembly 120 that may be disposed within a casing 112. The grainassembly 120 includes a grain 122 of combustible material and afirst-fire material (e.g., a reactive foil 124, discussed below)positioned relative to the grain 122. The combustible material of thegrain 122 may have a composition of a conventional decoy flare grain.Such a grain 122 may include, for example, magnesium and afluoropolymer-based material. Adding additional metals or other elementsto the combustible material of the grain 122 may alter the peak emissionwavelength emitted by the flare 110.

As shown in FIGS. 3 and 4, in some embodiments of the presentdisclosure, both the grain 122 of the grain assembly 120 and the casing112 may have an elongated shape. The casing 112 may have a first end114, i.e., an aft end, and a second end 116, i.e., a forward endopposite the aft end. The grain 122 of the grain assembly 120 may havean aft end 123A and a forward end 123B. The grain 122 of the grainassembly 120 may be initially positioned within the case 112 such thatthe aft end 123A of the grain 122 is proximate to the first end 114 ofthe casing 112 and such that the forward end 123B of the grain 122 isproximate to the second end 116 of the casing 112.

With continued reference to FIG. 4, a consumable weight 143 (i.e., aforward weight) may, along with the grain 122, be initially positionedwithin the casing 112 proximate to the second end 116 of the casing 112.An end cap 140 may, at least initially, enclose the consumable weight143 within the casing 112. The end cap 140 may be a plastic end cap andmay therefore be lighter weight and less expensive than conventionalweighted end caps 40 (FIGS. 1 and 2). The end cap 140 may be configuredto protect the consumable weight 143, the grain 122, and othercomponents of the flare 110 from coming into unwanted contact withsparks or other igniting materials.

The consumable weight 143 may be formed from a metal material dispersedin a matrix. FIG. 5 illustrates the consumable weight 143 in asimplified, enlarged view. The consumable weight 143 may include matrix202, which is an incinerable material, and metal material 200 within thematrix 202. The metal material 200 may be a metal-containing material,such as a metal, a metal oxide, a metal-containing compound, or themetal material 200 may be a metal-like material (i.e., a materialexhibiting a density and resistance to burning like that of a metal,metal oxide, or metal-containing compound). The metal material 200 doesnot burn or incinerate relative to the material of the matrix 202. Inother words, a temperature at which the metal material 200 burns isgreater than a temperature at which the matrix 202 burns. The metalmaterial 200 may be in the form of metal particles, a metal powder, orother non-consumable fill powder. In some embodiments, the metalmaterial 200 may exhibit an average particle size equal to or less thanabout 60 micrometers, such as from about 30 micrometers to about 50micrometers. In other embodiments, the metal material 200 may exhibit anaverage particle size larger than about 60 micrometers, though stillexhibiting a particle size configured to be small enough not pose adanger to airborne aircraft or ground-based buildings, vehicles, orpersonnel once the matrix 202 of the consumable weight 143 has beenconsumed.

For example, without limitation, the metal material 200 may be any oftungsten, bismuth, lead, tantalum, tungsten carbide, a metal oxide, analloy thereof, and a combination thereof. The metal oxide may be any oftungsten oxide, bismuth oxide, lead oxide, tantalum oxide, and acombination thereof.

The consumable weight 143 may have a density greater than or equal tothe density of brass (8.4 grams per cubic centimeter to 8.73 grams percubic centimeter). For example, in embodiments in which the metalmaterial 200 is tungsten, the metal material 200 may have a density ofabout 19.3 grams per cubic centimeter, and the consumable weight 143 mayhave a density greater than or about equal to (e.g., not significantlylower than) the density of brass. The metal material 200 may account forbetween about 50 weight percent and about 98 weight percent of a totalweight of the consumable weight 143. The consumable weight 143 may besubstantially nonreactive in that the material does not react uponimpact of the flare 110 with a target.

The matrix 202 of the consumable weight 143 may account for between 2weight percent and about 50 weight percent of the weight of theconsumable weight 143. The matrix 202 of the consumable weight 143 mayinclude a binder, such as a polymer binder. The binder may be a curablepolymer that is a liquid at a processing temperature of the consumableweight 143. Alternatively, the binder may include, partially orentirely, a solid or solids at room temperature (i.e., about 20 degreesCelsius). The binder may be an energetic or a nonenergetic material. Forexample, and without limitation, the binder of the matrix 202 mayinclude an energetic binder, such as glycidyl azide polymer (GAP) ornitrocellulose (NC). The binder may alternatively or additionallyinclude a nonenergetic binder, such as polyethylene glycol (PEG),polypropylene glycol (PPG), polybutadiene acrylonitrile (PBAN),hydroxyl-tellainated polybutadiene (HTPB), cellulose acetate butyrate(CAB), carboxyl-terminated polyethylene glycol succinate polyesterresin, a fluoroelastomer (e.g., VITON®), a fluorinated thermoplasticpolymer (e.g., THV 220), a co-polymer thereof, or a combination thereof

The matrix 202 may, optionally, include at least one of a plasticizer,an oxidizer, a burn rate catalyst, or other additives configured toprovide the consumable weight 143 with a desired spectral emissionduring incineration of the matrix 202, a desired burn rate, ballisticperformance, a desired intensity of the emitted light or heat, or otherproperties. The matrix 202 may also include at least one of theabove-mentioned additives to provide the desired safety, mechanical,ignition, processing, or curing properties to the consumable weight 143.For example, the matrix 202 of the consumable weight 143 may include upto about 15 weight percent plasticizer (i.e., from 0 weight percent toabout 15 weight percent plasticizer), up to about 20 weight percentoxidizer (i.e., from 0 weight percent to about 20 weight percentoxidizer), up to 5 weight percent burn rate catalyst (i.e., from 0weight percent to about 5 weight percent burn rate catalyst), or anycombination thereof, wherein the weight percentages are based on theweight of the consumable weight 143. The plasticizer may be energetic orinert. An energetic plasticizer may include, for example and withoutlimitation, glycidyl azide polymer (GAP); 1,2,4-butanetriol trinitrate(BTTN); bis(2,2-dinitropropyl)formal (BDNPF);bis(2,2-dinitropropyl)acetal (BDNPA); 1:1 mixture of BDNPF and BDNPA(BDNPA/F); nitroglycerine (NG); butyl nitroxyethylnitramine (BuNENA);other known energetic plasticizers, or combinations thereof An inertplasticizer may include, for example and without limitation, isodecylpelargonate (IDP), dioctyl adipate (DOA), other known inertplasticizers, or combinations thereof The oxidizer may include, forexample and without limitation, strontium nitrate, potassium nitrate,cesium nitrate, sodium nitrate, a perchlorate, other known oxidizers, orcombinations thereof The bum rate catalyst may include, for example andwithout limitation, iron oxide, a conductive carbon, other known burnrate catalysts, or combinations thereof In some embodiments, the matrix202 includes a GAP binder and at least one of a GAP plasticizer,strontium nitrate as the oxidizer, and iron oxide as the burn ratecatalyst. In some such embodiments, the consumable weight 143 mayinclude this matrix 202 and tungsten as the metal material 200. Thegrain 122 used with the consumable weight 143 of some such embodimentsmay also include GAP. In some embodiments, the matrix 202 is GAP and themetal material 200 is tungsten.

The consumable weight 143 may be sized and configured to have a weightabout equal to the weight of a conventional weighted end cap 40 (FIGS. 1and 2), be sized and configured such that the weight ratio of theconsumable weight 143 to the grain 122 is about equal to the weightratio of a conventional weighted end cap 40 to a conventional grainassembly 20, or both. For example, a conventional brass weighted end cap40 may weigh about 40 grams, and a conventional grain assembly 20 mayweigh approximately 120 to 135 grams, such that the weight ratio of theconventional weighted end cap 40 to the conventional grain assembly 20is about 1:3. Therefore, the flare 110 of the present disclosure may besized and configured such that the consumable weight 143 weighs about athird the weight of the grain 122 and first-fire material (e.g.,reactive foil 124).

The consumable weight 143 of the present flare 110 may be sized andconfigured to provide a stable trajectory of the flare 110 during use.The density of the consumable weight 143 may be selected and formulatedto be greater than or about equal to the density of a conventional brassweighted end cap 40. Accordingly, the consumable weight 143 may beformulated to have a density greater than or equal to about 8.4 gramsper cubic centimeter to about 8.73 grams per cubic center centimeter. Inother embodiments, the consumable weight 143 may have a density lessthan about 8.4 grams per cubic centimeter.

The consumable weight 143 may be formulated and configured such that thedensity is essentially uniform throughout the consumable weight 143. Forexample, the consumable weight 143 may be formulated such that the metalmaterial 200 is essentially uniformly distributed in the matrix 202 inwhich the metal material 200 is dispersed. In other embodiments, themetal material 200 may be more densely distributed in the matrix 202proximate to a front side 145A (FIG. 6) of the consumable weight 143.

FIG. 6 illustrates the consumable weight 143 and the grain 122 of aflare 110 separated from one another. The consumable weight 143 may beformed by casting processes, curing processes, compressive processes,extrusion processes, or other processes used to form conventional flaregrains. In the formed flare 110, the consumable weight 143 may beconnected proximate to the forward end 123B of the grain 122. Theconsumable weight 143 may be connected directly to the forward end 123Bof the grain 122. In some such embodiments, a rear side 145B of theconsumable weight 143 may be joined to the forward end 123B of the grain122. The consumable weight 143 may be joined to the grain 122 along aninterface 141 (FIG. 4) between the consumable weight 143 and the forwardend 123B of the grain 122. In other embodiments, the consumable weight143 may be seamlessly integrated with the grain 122. Accordingly, informing the flare 110, in some embodiments, the consumable weight 143and the grain 122 may be formed simultaneously, e.g., co-cured, to forma unified flare 110. In other embodiments, the consumable weight 143 maybe separately folined and later attached to the grain 122, such as byadhering (i.e., bonding) the consumable weight 143 to the grain 122. Thebinder in the matrix 202 of the consumable weight 143 may providesufficient adhesion to join the consumable weight 143 to the grain 122.Alternatively, an adhesive composition may be used to join theconsumable weight 143 and the grain 122. In one embodiment, the binderof the matrix 202 is the same as a binder within the grain 122,improving adhesion between the consumable weight 143 and the grain 122.The consumable weight 143 and the grain 122 may be formed usingconventional grain-forming methods, whether formed together or formedseparately and then joined. For example, the consumable weight 143 andthe grain 122, whether formed together or formed separately and joined,may be formed into desired shapes or configurations by casting,pressing, extrusion, molding, curing, machining, or other conventionaltechniques.

A separately formed consumable weight 143 may be retrofitted to aconventional grain 22 (FIGS. 1 and 2) of a conventional flare 10 toreplace the conventional weighted end cap 40. In some such embodiments,the consumable weight 143 may be formed to be about the same size andshape as the conventional weighted end cap 40 such that the consumableweight 143, according to embodiments of the present disclosure, may beattached to a conventional grain 22 and used in a conventional casing12. Thus, the consumable weight 143 may be a drop-in replacement for theconventional weighted end cap 40 of the conventional flare 10.Therefore, the consumable weight 143 may be adherable to a grain 122 ofa flare 110.

While FIGS. 3, 4, and 6 show that no portion of the consumable weight143 is received within a portion of the grain 122, in some embodiments,the consumable weight 143 may be attached to the grain 122 by anelongated rod (e.g., elongated rod 42 (FIG. 2)). The elongated rod isconnected to the consumable weight 143 and received within an internalbore 144 defined in the grain 122.

The consumable weight 143 may be formed so as to have a cross-sectionalshape similar or identical to the cross-sectional shape of the grain122. FIGS. 7A through 7E illustrate a variety of cross-sectional shapesin which the consumable weight 143 and/or the grain 122 may be formed.The consumable weight 143, the grain 122, 122′, 122″, 122′″, 122″″, orboth may include one or more grooves 126, 126′, 126″″ along exteriorlateral surfaces 128. The consumable weight 143, the grain 122, 122′,122″, 122′″, 122″″, or both may, optionally, include an internal bore144 configured to receive an elongated rod. Therefore, the consumableweight 143 may have a cross-sectional shape of a conventional grain 22(FIGS. 1 and 2), regardless of whether the internal bore 144 is utilizedto receive the elongated rod. The internal bore 144, along with thegrooves 126, 126′, 126″″ may be configured to enable combustion,incineration, or both of the material forming the grain 122, 122′, 122″,122′″, 122″″, the matrix 202, or both of the consumable weight 143. Inother embodiments, such as that illustrated in FIG. 7E, the consumableweight 143, the grain 122″″, or both do not include an internal bore144.

With reference to FIGS. 8 and 9, exterior lateral surfaces 128 of theconsumable weight 143 and/or grain 122 may be surrounded, at leastpartially, by a first-fire material such as a reactive foil 124. Thisfirst-fire material is included within the grain assembly 120 of theflare 110. As shown in FIG. 8, in some embodiments, the reactive foil124 of the grain assembly 120 may come into direct contact with onlysome of exterior lateral surfaces 128 of the consumable weight 143, thegrain 122, or both. As shown in FIG. 9, in some embodiments, thereactive foil 124 of the grain assembly 120′ may be in direct contactwith all exterior lateral surfaces 128 of the consumable weight 143, thegrain 122, or both. Notably, though FIGS. 8 and 9 depict the grainassembly 120, 120′ with reactive foil 124 in connection with the grain122, a front elevation or cross-sectional view of the consumable weight143 in connection with the reactive foil 124 would be an equivalent viewto those depicted in FIGS. 8 and 9 of the grain assembly 120, 120′. Inother embodiments, the first-fire material may include combustiblepowders, slurries, sol-gel compositions, or any combination thereof. Thefirst-fire material may be configured to enable ignition of one or bothof the grain 122 and the matrix 202 of the consumable weight 143.

Methods of using a flare 110 may involve a series of ignitions ofvarious components within the flare 110. With reference to FIG. 4, animpulse charge device 130 may be provided at or within the first end 114of the casing 112, although, in some embodiments, such an impulse chargedevice 130 may not be coupled to the flare 110 until the flare 110 isready to be deployed (e.g., if the flare 110 includes a decoy flare, theimpulse charge device 130 may not be coupled to the flare 110 until theflare 110 is mounted in an aircraft). The impulse charge device 130 maybe configured to force the grain assembly 120, with consumable weight143 attached thereto, out from the second end 116 of the casing 112 uponignition of the impulse charge device 130. As shown in FIG. 4, the decoyflare 110 may include a piston member 132 disposed within the casing 112between the impulse charge device 130 and the grain assembly 120.

In some embodiments of the present disclosure, the piston member 132 maybe part of an ignition assembly 136 (often referred to in the art as an“ignition sequence assembly,” a “safe and arm igniter,” or a “safe andarm ignition assembly”). In some embodiments, the flare 110 may includean ignition assembly 136 having a mechanism configured to preventignition of the reactive foil 124 (or other first-fire material), thegrain 122, and the consumable weight 143 until the grain assembly 120and consumable weight 143 have been substantially ejected from thecasing 112 by the impulse charge device 130. In other embodiments, theflare 110 may include an ignition assembly 136 that is configured tocause ignition of the reactive foil 124, or other first-fire material,and the grain 122 before the grain assembly 120 and consumable weight143 have been substantially ejected from the casing 112 by the impulsecharge device 130, or as the grain assembly 120 and consumable weight143 are being ejected from the casing 112 by the impulse charge device130. By way of example and not limitation, the ignition assembly 136 mayinclude a first igniter material 134 of combustible material that isattached or coupled to the piston member 132. The first igniter material134 may include, for example, a boron- or magnesium-based material.Combustion of the first igniter material 134 may be initiated uponignition of the impulse charge device 130, and combustion of the firstigniter material 134 may cause ignition of the grain assembly 120. Byway of a more particular example and not limitation, combustion of thefirst igniter material 134 may cause ignition of the first-firematerial, e.g., the reactive foil 124, and the reactive foil 124 maycause ignition of the grain 122. The first-fire material, e.g., thereactive foil 124, may also cause ignition of the consumable weight 143.Alternatively, the combustion of the grain 122 may cause ignition of theconsumable weight 143. Combustion of the grain 122 may cause ignition ofthe consumable weight 143 after the grain assembly 120 and theconsumable weight 143 have been ejected from the casing 112.

In use and operation of the flare 110, the grain 122 may be ignited toconsume the combustible material of the grain 122, and the consumableweight 143 may be ignited to incinerate the matrix 202 (FIG. 5).Incinerating the matrix 202 may release the metal material 200. Themetal material 200 may not be consumed during use and operation but mayfall to the ground as particles (e.g., solid particles, friableparticles, metal particles, metal oxide particles, or the like) that arerelatively harmless to airborne aircraft or ground-based buildings,vehicles, or personnel. The consumable weight 143 may be configured sothat the matrix 202 will complete incineration only after the grain 122has been fully consumed. The burn rate of the consumable weight 143 maybe tailored such that the consumable weight 143 provides stability andweight to the forward end of the flare 110 during use and operation ofthe flare 110. However, the burn rate may be sufficiently fast that theconsumable weight 143 is substantially consumed (i.e., the gaseousbyproducts, the friable material, the unreacted products, or anycombination thereof are produced) before contacting airborne aircraft orground-based buildings, vehicles, or personnel. The consumable weight143, upon combustion, may break into particles or ash of a sufficientsize that the particles or ash do not damage airborne aircraft orground-based personnel or other property. Thus, the flare 110 mayproduce minimal amounts of debris that pose a danger to airborneaircraft or ground-based personnel or other property.

The flare 110 may be configured to be released from an airborneaircraft. In other embodiments, the flare 110 may be configured to besurface deployed so as to be projected into the air by anearth-supported device. The flare 110 may be, for example, a propulsiveflare or a low thrust decoy flare. In either regard, the flare 110 maybe configured such that ignition of the grain 122 will result insubstantially full consumption of the combustible material of the grain122 and such that ignition of the consumable weight 143 will result inincineration of substantially all of the matrix 202 of the consumableweight 143 before combustion products of the consumable weight 143 comeinto contact with airborne aircraft or any earth-supported object, suchas buildings on the ground, people on the ground, watercraft in bodiesof water, people in bodies of water, or the ground surface itself. Thecombustion products of the consumable weight 143, following incinerationof the matrix 202, may include the gaseous byproducts, the friablematerial, such as ash, and unreacted products, such as the metalmaterial 200. The gaseous byproducts may include, among otherbyproducts, carbon dioxide, carbon monoxide, water, or combinationsthereof In addition, smoke or light may be produced. The combustionproducts do not include the casing 112, which may be configured to beretained within the aircraft when the flare 110 is released. Therefore,the flare 110 is configured such that low amounts of debris are producedfrom the combustion of its components, which are unlikely to causedamage if ingested in engines of aircraft flying below or behind theaircraft from which the flare 110 is released and are unlikely to causeinjury or damage to earth-supported objects, including people. Inaddition to flares 110, the consumable weight 143 may be used in otherprojectiles having weighted components (i.e., brass or other metalcomponents) such that a reduction in falling debris from brass or othermetal components in the projectiles is achieved.

The metal material 200 may be formed of fine pieces of material, such asa metal powder. Therefore, when the metal material 200 is released bythe incineration of the matrix 202, the combustion products of theconsumable weight 143 include fine pieces of the non-consumed metalmaterial 200 and ash from the incinerated matrix 202. Thus, thelikelihood of unwanted contact between falling solid debris and otheraircraft, people, or objects below is minimized or greatly reducedcompared to the conventional flare 10 (FIGS. 1 and 2) in whichconsumption of the grain 22 leaves a falling, essentially-solid,weighted end cap 40. The metal material 200 may exhibit an averageparticle size equal or less than about 60 micrometers. For example, themetal material 200 may exhibit an average particle size in the range offrom about 30 micrometers to about 50 micrometers, inclusive. Thecombustion products of the consumable weight 143 following incinerationmay, therefore, include solid matter not exceeding about 60 micrometersin average particle size, e.g., solid matter with an average particlesize in the range of from about 30 micrometers to about 50 micrometers.In other embodiments, the metal material 200 may exhibit an averageparticle size larger than about 60 micrometers, though still exhibitinga particle size configured to result in combustion products of theconsumable weight 143, following incineration, that include solid matterof a small enough particle size, in light of the weight, friability,density, or other properties of the solid matter, that will not pose adanger to airborne aircraft or ground-based buildings, vehicles, orpersonnel.

In some embodiments of the present disclosure, the flare 110 may beconfigured as a decoy flare, and the combustible material of the grain122 and/or the matrix 202 of the consumable weight 143 may be configuredto emit electromagnetic radiation (upon combustion of the grain 122,consumable weight 143, or both) having a peak emission wavelength withinthe infrared region of the electromagnetic radiation spectrum (i.e.,between about 0.7 microns and about 100 microns). In additionalembodiments, the flare 110 may be configured for signaling,illumination, or both, and may be configured to emit a peak emissionwavelength within the visible region of the electromagnetic radiationspectrum (i.e., between about 400 nanometers and about 700 nanometers).In yet other embodiments, the flare 110 may be configured to emit a peakemission wavelength within the ultraviolet region of the electromagneticradiation spectrum.

The composition of the consumable weight 143 may be selected so as toachieve the desired electromagnetic radiation emissions, the desiredburn rate, and other properties of an ignited flare 110.

FIG. 10 illustrates another embodiment of the grain assembly 120 of theflare 110 to which the ignition assembly 136 is attached. As shown, thefirst fire material, e.g., the reactive foil 124 covers the grain 122(FIG. 4) of the grain assembly 120 as well as the consumable weight 143.The illustrated grain assembly 120 and consumable weight 143 areconfigured to be positioned within a casing 112 (FIG. 4) prior toignition.

Accordingly, disclosed are a flare, a forward weight, a composition of anonreactive material, a method for fabricating a flare, and a method forusing a flare.

While the present devices, compositions, and methods may be susceptibleto various modifications and alternative forms, specific embodimentshave been shown by way of example in the drawings and have beendescribed in detail herein. However, it should be understood that theinvention is not intended to be limited to the particular formsdisclosed. Rather, the invention includes all modifications,equivalents, and alternatives falling within the scope of the inventionas defined by the following appended claims and their legal equivalents.For example, elements and features disclosed in relation to oneembodiment may be combined with elements and features disclosed inrelation to other embodiments of the present disclosure.

1. A consumable weight component for a flare, the consumable weightcomponent comprising a metal material within a matrix in a solid phaseof the consumable weight.
 2. The consumable weight component of claim 1,wherein the metal material is essentially uniformly dispersed within thematrix.
 3. The consumable weight component of claim 1, wherein the metalmaterial is more densely dispersed within the matrix proximate to afront side of the consumable weight component.
 4. The consumable weightcomponent of claim 1, wherein the matrix comprises an energetic binder.5. The consumable weight component of claim 1, wherein the matrixcomprises a nonenergetic binder.
 6. The consumable weight component ofclaim 1, wherein the metal material is suspended within the matrix andthe metal material comprises a metal, a metal alloy, or a metal oxide.7. The consumable weight component of claim 1, wherein the metalmaterial is a powdered metal material.
 8. The consumable weightcomponent of claim 1, wherein the metal material exhibits an averageparticle size not exceeding 60 micrometers.
 9. A consumable weightcomponent for a flare, the consumable weight component comprising ametal material dispersed within a matrix and defining at least one of:an internal bore, or at least one groove in at least one exteriorlateral surface of the consumable weight.
 10. The consumable weightcomponent of claim 9, wherein the consumable weight component definesthe internal bore, the internal bore extending through a height of theconsumable weight component.
 11. The consumable weight component ofclaim 9, wherein the consumable weight component defines grooves in theexterior lateral surfaces of the consumable weight.
 12. The consumableweight component of claim 9, wherein the metal material comprises atleast one of tungsten, bismuth, lead, or tantalum.
 13. The consumableweight component of claim 9, wherein the metal material comprises ametal oxide selected from the group consisting of tungsten oxide,bismuth oxide, lead oxide, and tantalum oxide.
 14. The consumable weightcomponent of claim 9, wherein the matrix comprises a glycidyl azidepolymer (GAP) binder and at least one of a GAP plasticizer, strontiumnitride, or iron oxide.
 15. The consumable weight component of claim 14,wherein the metal material comprises tungsten.
 16. A method of forming aflare having a consumable weight component, the method comprising:forming a consumable weight component defining a cross-sectional shape,comprising: dispersing a metal material within a matrix, the matrixforming a solid phase of the consumable weight component; and joiningthe consumable weight component to a forward end of a grain alsodefining the cross-sectional shape.
 17. The method of claim 16, furthercomprising disposing a reactive foil about exterior lateral surfaces ofthe consumable weight component and the grain.
 18. The method of claim17, wherein disposing a reactive foil about exterior lateral surface ofthe consumable weight component and the grain comprises disposing thereactive foil to directly contact only some of the exterior lateralsurfaces.
 19. The method of claim 16, wherein forming a consumableweight component and joining the consumable weight component to aforward end of a grain comprise simultaneously co-curing material of thematrix of the consumable weight component and material of the grain toform a unified flare comprising the consumable weight componentseamlessly joined to the grain.
 20. The method of claim 16, whereinforming a consumable weight component defining a cross-sectional shapecomprises at least one of casting, pressing, extruding, molding, curing,or machining to define the cross-sectional shape, the cross-sectionalshape exhibited by the matrix containing the metal material.